Communications Connector with Improved Contacts

ABSTRACT

A communication jack is provided with plug interface contacts that have a short conductive signal pathway between a plug-jack interface and crosstalk compensation provided on a printed circuit board within the jack. Contacts of the jack are specially designed not to take a permanent set if a six-position plug or an eight-position plug is inserted into an eight-position jack. A printed circuit board in the jack is placed at an angle, shortening the conductive pathway between plug contacts and the printed circuit board.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. application Ser. No. 12/366,804, filed Feb. 6, 2009, which claims priority to U.S. Provisional Patent Application Serial No. 61/027,123 filed Feb. 8, 2008 which is herein incorporated by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates generally to electrical connectors, and more particularly, to a modular communication jack having an improved contact arrangement for reducing net crosstalk and accommodating different types of plugs.

BACKGROUND OF THE INVENTION

In the communications industry, as data transmission rates have steadily increased, crosstalk due to capacitive and inductive couplings among the closely spaced parallel conductors within the jack and/or plug has become increasingly problematic. Modular connectors with improved crosstalk performance have been designed to meet the increasingly demanding standards. Many of these improved connectors have included concepts disclosed in U.S. Pat. No. 5,997,358, the entirety of which is incorporated by reference herein. In particular, recent connectors have introduced predetermined amounts of crosstalk compensation to cancel offending near end crosstalk (NEXT). In some connectors, stages of compensation are used to account for phase shifts from propagation delay resulting from the distance between the compensation zone and the plug/jack interface. As a result, the magnitude and phase of the offending crosstalk is preferably offset by the compensation, which, in aggregate, has an equal magnitude, but opposite phase from the offending crosstalk.

Recent transmission rates, including those in excess of 500 MHz, have exceeded the capabilities of the techniques of existing jacks. Thus, jacks having improved compensation characteristics are needed.

There is a phase shift from an installed plug to the compensation zones in a jack which is dependent on the distance from the plug/jack electrical interface to the printed circuit board (PCB) which contains the compensation elements, and the dielectric of the surrounding materials. This phase shift is proportional to frequency and the magnitude of required compensation is dependent on the magnitude of phase shift. It is therefore advantageous to minimize this distance and phase shift to maximize the frequency range over which sufficient compensation is attained.

It is therefore advantageous to minimize the length of that portion of the jack contacts which electrically connects an installed plug to the PCB. However, a simple short cantilever contact is not mechanically sound.

An additional problem encountered in the design of electrical communication jacks is the fact that different types of plugs may be inserted into a jack—intentionally or unintentionally. For example, it is possible for a six-contact plug to be inserted into an eight-contact jack. In such a scenario, the six-contact plug will generally have a housing that will cause the first and eighth contacts—the outermost contacts—of the jack to flex farther than they would if an eight-contact plug were inserted into the jack. This can cause the outermost contacts of an eight-contact jack to take a permanent set, reducing or eliminating those contacts' ability to make proper contact with the first and eighth contacts of eight-contact plugs when they are later inserted. It is desirable to have a communication jack in which all contacts, including the outermost contacts, will not take a permanent set if a connector with six contacts is inserted into the jack.

BRIEF DESCRIPTION OF FIGURES

FIG. 1 is a front perspective view of a communication jack;

FIG. 2 is a perspective view of a printed circuit board (PCB) and contact assembly;

FIG. 3 is a cutaway side view through an outer plug interface contact of a jack showing an eight-contact plug inserted into the jack;

FIG. 4 is a cutaway side view through an outer plug interface contact of a jack showing a six-contact plug inserted into the jack;

FIG. 5 is a cutaway side view through a plug interface contact of a jack showing a plug inserted into the jack;

FIG. 6 is a cutaway side view through a plug interface contact of an alternative embodiment of a jack showing a plug inserted into the jack;

FIG. 7 is a bottom perspective view of plug interface contacts in contact with plug contacts;

FIG. 8 is a plan view of a PCB showing conductive traces;

FIG. 9 is a cross-sectional view of a PCB along the line 9-9 of FIG. 8;

FIG. 10 is a rear perspective view of conductive traces of a PCB;

FIG. 11 is a front perspective view of conductive traces of a PCB;

FIG. 12 is a perspective view of conductive layers of a plate capacitor; and

FIG. 13 is a side view of a simulated cantilevered plug interface contact.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 is a perspective front view of a communication jack 10 according to one embodiment of the present invention. The communication jack 10 has a housing 12 and an opening 14 for accepting a plug. Plug interface contacts 16 a-16 h are provided within the opening 14 and positioned to make contact with plug contacts of an inserted plug.

As shown in FIG. 2, the plug interface contacts 16 a-16 h are inserted into a PCB 18 at compliant sockets 20 a-20 h. Compliant pins (not shown in FIG. 2) hold the plug interface contacts 16 a-16 h within the compliant sockets 20 a-20 h.

In one embodiment, the compliant sockets 20 a-20 h serve merely as mechanical attachments for the plug interface contacts 16 a-16 h and do not provide electrical connections between the compliant plug interface contacts 16 a-16 h and the PCB 18. In this embodiment, electrical connections between the plug interface contacts 16 a-16 h and the PCB are made at conductive pads 22 a-22 h. FIG. 2 shows only conductive pad 22 h; the conductive pads 22 a-22 h are more easily seen in FIG. 7.

Insulation displacement contacts (IDCs) 24 a-24 h electrically connect first through eighth wires, respectively, of a communication cable (not shown) to the PCB 18. The IDCs 24 a-24 h are electrically and mechanically connected to the PCB 18 at plated-through IDC vias 26 a-26 h, respectively. The plug interface contacts, 16 a-16 h, the IDCs 24 a-24 h, and the PCB 18 form a jack contact assembly 28. Electrically conductive traces between the plug interface contacts 16 a-h and the IDCs 24 a-h are provided on the PCB 18, as shown in FIGS. 8-11.

As shown in FIG. 3, the first and eighth plug interface contacts 16 a and 16 h are designed to mate with contacts of an inserted plug and also to withstand greater deflection without unacceptable deformation of the plug interface contacts. FIG. 3 illustrates the eighth plug interface contact 16 a making contact with a plug contact 30 h of a plug 32 that has been inserted into the jack 10. In this embodiment, plug interface contact 16 a is constructed identically to plug interface contact 16 h. The plug interface contact 16 a is physically attached to the PCB 18 at compliant pin 19 a. The plug interface contact 16 a bends to accommodate the plug, while still maintaining proper contact force on both the plug contact 30 a and the conductive pad 22 a. The plug interface contact 16 a contacts the plug contact 30 a at a plug/jack interface 34 a. Thus, the conductive pathway of a signal through the plug interface contact 16 a is between the plug/jack interface 34 a and a contact/pad interface 36, where the plug interface contact 16 a contacts the conductive pad 22 a. The conductive pathway is shown as region “A” in FIG. 3. This conductive pathway is short, allowing compensation within the PCB 18 to be close to the plug contact 30 a. Shortening this conductive pathway reduces the phase angle change between offending crosstalk in the plug 32 and compensation on the PCB 18, increasing the effectiveness of the compensation across a wide frequency range.

The PCB 18 is positioned at an angle from the vertical, and this tilting of the PCB also facilitates a shortening of the conductive pathway “A.” In the embodiment shown in FIG. 3, the PCB 18 is tilted approximately 15° from the vertical. Greater or lesser angles may be provided as required by specific plug and jack designs. The IDCs 24 are provided with bent portions as shown at 25 a and 25 b to accommodate the angle of the PCB 18.

The plug interface contact 16 a is designed with two radii: a first radius 38 and a second radius 40. These radii are designed to collapse and survive stress from a large deflection, as when a six-position plug 42 is inserted into the jack 10 as shown in FIG. 4.

The plug interface contacts 16 a and 16 h can deflect a large distance without taking a permanent set, thereby enabling their continued use with an eight-position plug 32 as shown in FIG. 3 after a six-position plug 42 has been inserted into the jack as shown in FIG. 4.

FIG. 5 is a cross-sectional side view through another plug interface contact 16 b. Plug interface contact 16 b as illustrated is representative of the similarly constructed six centrally disposed plug interface contacts 16 b-16 g. FIG. 5 shows the plug interface contact 16 b making electrical contact with a plug contact 30 b of an eight-position plug 32 at a plug-jack interface 34 b. The plug interface contact 16 b is physically attached to the PCB 18 at compliant pin 19 b and electrically contacts the PCB 18 at conductive pad 22 b. The plug interface contact 16 b is provided with curves that allow the plug interface contact 16 b to flex upon insertion of a plug 32 without being permanently deformed and to maintain proper contact force with the plug contact 30 b and the conductive pad 22 b. In the embodiment shown in FIG. 5, three curves are used to maintain proper contact force: a first curve 44, a second curve 46, and a third curve 48.

A first curve 44 is positioned between the compliant pin 19 g and a second curve 46, where the plug interface contact 16 b contacts the conductive pad 22 b. The first curve assures that proper contact force is maintained between the second curve 46 and the conductive pad 22 b. In addition to allowing electrical contact between the plug interface contact 16 b and the conductive pad 22 b, the second curve 46 guides the plug interface contact 16 b away from the PCB 18 and toward the plug contact 30 b. The third curve 48 is at the plug-jack interface 34 b, and it both enables the plug interface contact 16 b to make electrical contact with the plug contact 30 b and guides the plug interface contact 16 b away from the plug contact 30 b to its endpoint 50. In the embodiment shown in FIG. 5, the endpoint 50 is free-floating. The plug interface contact 16 b is restricted from side-to-side movement by a comb element 52, which is also shown in FIG. 1. Plug interface contacts 16 b-16 g are able to make electrical contact with plug contacts of either a six-position plug or an eight-position plug.

FIG. 6 shows an alternative embodiment of a plug interface contact 54 b. The plug interface contact 54 b is similar to the plug interface contact 16 b shown in FIG. 5, except that the endpoint 56 of the plug interface contact 54 b is provided with an extra curve 58. The curve 58 rides along a cantilevered support 60 that is an extension of the housing 12 of the jack 10. The design of the plug interface contact 54 b provides an additional spring mating force between the plug contact 30 b and the plug interface contact 54 b.

FIG. 7 is a bottom perspective view that shows plug interface contacts 16 a-16 h of a jack contact assembly 28 making electrical contact with plug contacts of an eight-position plug 32. Additional structure of the jack has been removed from FIG. 7 so that the conductive elements are more clearly seen. The conductive pads 22 a-h can be seen in electrical contact with the plug interface contacts 16 a-h.

FIGS. 8-11 show the conductive traces 62 a-h provided on PCB 18 that electrically connect the conductive pads 22 a-h to the plated-through vias 26 a-h where the IDCs 24 a-h are inserted. As shown in FIG. 8, several plate capacitors 64 are provided in connection with the conductive traces 62. The conductive traces 62 and the plate capacitors 64 are sized and positioned on the PCB 18 so that the net inductive and capacitive crosstalk provided by the conductive traces 62 and plate capacitors 64 has approximately the same magnitude as the offending crosstalk produced in a plug, with the opposite polarity.

According to one embodiment, conductive traces 62 a-h are provided in eight conductive layers. The solid lines in FIG. 8 show portions of conductive traces that are provided on a first layer, and the dotted lines show portions of conductive traces that are provided on an eighth layer. At some portions of the PCB 18, traces on the first layer and traces on the eighth layer overlap, and in those areas a solid line is shown.

FIG. 9 shows a cross-sectional view of the PCB 18 through the line 9-9 of FIG. 8. Plated-through vias 26 b and 26 f are shown in FIG. 9, as are portions of first through eighth conductive traces 62 a-h respectively associated with the first through eighth conductive pads 22 a-h and IDCs 24 a-h.

FIGS. 10 and 11 show perspective views of conductive traces 62 a-h of a PCB 18. Several layer-to-layer vias 66 are provided to allow conductive traces to transition from one conductive layer to another. FIGS. 10 and 11 illustrate that plate capacitors 64 may incorporate conductive plates positioned on several conductive layers. FIG. 11 shows the conductive pads 22 a-22 h.

FIG. 12 is a perspective view of a plate capacitor 64 according to one embodiment of the present invention. The plate capacitor 64 of FIG. 12 comprises four conductive layers 68 a-d. The four conductive layers 68 a-d include outer layers 68 a and 68 d and inner layers 68 b and 68 c. Dotted lines are used in FIG. 12 to illustrate portions of the layers 68 a-d that would be hidden due to the perspective view. Dielectric layers are between the conductive layers, but for clarity the dielectric material has been omitted from FIG. 12. The plate capacitor 64 is constructed with the inner layers 68 b and 68 c having a larger surface area than the outer layers 68 a and 68 d. This results in a reduction in variation in capacitance from one circuit board to another due to registration tolerances in the manufacturing process.

The design of plug interface contacts 16 a-16 h as best illustrated in FIGS. 2 and 5 allows for superior maintenance of contact force between the plug interface contacts 16 a-16 h and the plug contacts 30 of inserted plugs, as compared to a simpler cantilevered plug interface contact design 70 as shown in FIG. 13. Simulations of plug insertion performed using Ansys™ engineering simulation software have shown that contacts 16 b-16 g as shown and described above will maintain proper contact force with future plug contacts after a plug has been inserted into and removed from a jack. Similar simulations show that the cantilevered plug interface contact design 70 will fail to maintain a proper contact force with future plug contacts of inserted plugs, after even one simulated insertion and removal of a plug. The plug interface contact design 70 was chosen for simulation because both the simulated design and the plug interface contacts 16 b-16 g have the same signal path length between plug contacts and a printed circuit board in the jack.

For example, it is desirable to maintain at least 100 grams of force (go as a contact force between a plug interface contact and a plug contact. Following insertion and removal of a plug, plug interface contacts having the design of the plug interface contacts 16 b-16 g were able to make 159 gf of contact force with a contact of a later-inserted simulated plug. A simulation of the simpler cantilevered plug interface contact design 70 shown in FIG. 13, however, showed that the simpler cantilevered plug interface contact 70 would only exert 37 gf of contact force on a contact of a later-inserted plug.

Similar simulations were performed on modeled versions of the outermost plug interface contacts 16 a and 16 h as best shown in FIGS. 2, 3, and 4. These simulations were performed using Ansoft™ software to simulate the effect of first inserting a six-position plug into a jack, and later inserting an eight-position plug into the jack. This simulated the housing of a six-position plug bending the contacts 16 a and 16 h to a greater extent than an eight-position plug would. Under this simulation, even after being bent by the housing of the six-position plug, the outermost contacts 16 a and 16 h were able to later maintain a contact force of 141.5 gf on contacts of an eight-position plug. An acceptable contact force of 122.9 gf between the modeled contacts and the conductive pads 22 a and 22 h was also maintained upon insertion of the modeled eight-position plug after the simulated insertion and removal of the six-position plug.

It is to be understood that modifications to the shown embodiments may be made while still falling within the scope of the present invention. For example, while the above-described embodiments show eight-contact jacks, it is to be understood that jacks according to the present invention may be provided with more or fewer than eight contacts, depending on the particular application for the jack, with proper modifications made to accommodate more or fewer contacts. 

1. A communications connector for mating with a communications plug having contacts, the connector comprising: a printed circuit board (PCB), the PCB comprising a first contact pad; and a first plug interface contact (PIC), the first PIC rigidly attached to the PCB at a first end of the PIC, the first PIC also comprising a first bend with a first radius and a second bend with a second radius, the second bend proximate to a second end of the first PIC and the first PIC configured to contact the first contact pad at a point along the second bend.
 2. The communications connector of claim 1 wherein the PCB further comprises a second contact pad and further comprising a second PIC, the second PIC rigidly attached to the PCB at a first end of the second PIC, the second PIC also comprising a first bend with a first radius and a second bend with a second radius, the second bend proximate to a second end of the second PIC and the second PIC configured to contact the second contact pad at a point along the second bend.
 3. The communications connector of claim 2 further comprising an array of cantilever PICs, the first PIC, second PIC, and array of cantilever PICs arranged in a row such that the first PIC and the second PIC are on opposite sides of the array of cantilever PICs, allowing the plug contacts to each contact a corresponding PIC when the communications plug is inserted into the communications connector.
 4. The communications connector of claim 3 wherein the PCB further comprises an array of contact pads, each PIC of the array of PICs configured to make electrical contact with an associated contact pad of the array of contact pads.
 5. The communications connector of claim 1 wherein the first radius and the second radius are configured to collapse and survive stress from a large deflection. 